INSTRUCTION MANUAL

ZA737/757
CHAPI (STYLE A)
Revision: 2.03

For Spare Parts or Technical Assistance, Call:

Flight Light, Inc.
2708 47th. Ave
Sacramento, CA 95822
(916) 394-2800
(916) 394-2809 (fax)
E-mail: sales@flightlight.com
See: www.flightlight.com for complete catalog.

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INSTRUCTION MANUAL INDEX

1.00 SITING AND AIMING
1.10 Signal Presentation
1.20 General Site Considerations
1.30 Threshold Crossing Height (TCH)
1.40 Glide Path Angle
1.50 The CHAPI Obstacle Clearance Surface
1.60 Other Siting Dimensions & Tolerances
1.61 Azimuth Aiming
1.62 Mounting Height Tolerances
1.63 Tolerance Along Line Perpendicular to Heliport

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2.00 INSTALLATION
2.10 Determination of Proper Light Boxes
2.11 CHAPI Light Housing Location
2.20 Installation of Footers and Mounting Pads
2.21 Align and Secure the Base Unit
2.30 Interconnect Wiring
2.31 Home Run Wiring Choice
2.32 Above Ground Wiring Protection
2.33 Wiring Connections
2.40 Adjustment of the Light Housing Assembly
2.41 L-881 (two LHA system)
2.42 L-880 (four LHA system)
2.50 Color Filter Installation and Electrical Adjustment
2.51 Lamp Installation
2.52 Interlock Adjustment
2.60 Flight Check

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3.00 SYSTEM DESCRIPTION AND COMPONENTS

3.00 Principal Components
3.10 Light Housing Assembly
3.20 Power Adapter
3.30 Day/Night Control
3.40 Power Protection Circuit
3.50 Tilt Detection Circuit
3.60 Lens Heater Circuit
3.70 Alignment & Aiming Device Calibration

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4.00 TROUBLESHOOTING

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5.00 DRAWINGS & ADDENDUMS (attached)

5.10 ZA757/737 Power Adapter parts layout (FLP28400J), Class I & II
5.11 ZA757 Power Adapter wiring diagram (FLP28401E)
5.20 ZA737 Power Adapter wiring diagram (FLP28401H)
5.21 ZA757 Power Adapter wiring diagram 120VAC Option (FLP28401J)

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5.22
5.50
5.51
5.52
5.53
5.60
5.70
5.80
5.81
5.90
5.91
5.92
5.93

ZA737 Power Adapter wiring diagram (FLP28401H-120VAC)

120VAC Option, 2 or 4 LHA
ZA757 Installation wiring diagram (FLP28403H)
ZA737 Installation wiring diagram (FLP28403I)
ZA757 LHA Wiring diagram (FLP1006A) Class I (FLP1006A)
ZA737 LHA Wiring diagram (FLP1006B) Class I
ZA757 LHA Wiring diagram (FLP28404D) Class I
ZA737 LHA Wiring diagram (FLP28404H) Class II
Power Adapter Enclosure (FLP28405A)
Frangible mounting accessories (FLP28406B)
ZA757 Base Mounting Guide (FLP28407A)
ZA737 Base Mounting Guide (FLP28407B)
ZA757 Filter Installation (FLP28408)
ZA737 Filter Installation (FLP28408A)

PARTS LIST

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SECTION ONE Siting and Aiming

Flight Light, Incorporated is not a provider of heliport engineering design services. Flight Light recommends
qualified personnel performs the analysis, design and implementation of your CHAPI installation. All
installation descriptions and examples in this manual are for illustrative purposes and do not take into
account the conditions present at any specific site location.
1.10 Signal Presentation
The heliport approach path indicator (CHAPI) is a system of two identical Light Housing Assemblies (LHA)
placed on the left of the heliport, aimed outward into the approach zone (see Figure 1). The front face of
each unit is perpendicular to the helipad centerline. The boxes are positioned and aimed to produce the
signal presentation described below.
L-881 Two Box System: when making an approach, the helicopter pilot will see:

1.20 General Site Considerations

When viewed from the approach end, the CHAPI system shall be located on the left side of the helipad. In
the event of siting problems, such as conflicts with obstructions, the CHAPI may be located on the right side
of the helipad. The CHAPI must be sited and aimed so that it defines an approach path with adequate
clearance over obstacles and a minimum Threshold Crossing Height (TCH). When an ILS glide slope is
not present, the designer must determine a position and aiming for the CHAPI which will produce the
required threshold crossing height and clearance over obstacles in the approach area.
1.30 Threshold Crossing Height (TCH)
The TCH is the height of the lowest on-course signal at a point directly above the intersection of the runway
centerline and the threshold. The minimum allowable TCH varies according to the height group of aircraft
that uses the runway. The CHAPI approach path must provide the proper TCH for the most demanding
height group that uses the runway.
1.40 Glide Path Angle
The visual glide path angle is the center of the on-course zone, and is normally 6 degrees when measured
from horizontal for a CHAPI.

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Figure 1 Helipad Layout for CHAPI

1.50 The CHAPI Obstacle Clearance Surface
The CHAPI obstacle clearance surface is established to provide the pilot with a minimum clearance over obstacles
during approach. Obstacle clearance slope, through which no object shall protrude, can be defined as 1 below the
angle which defines the lower boundary of the on-slope indication, for a distance of 17.40 miles, in an area generally
bounded by 15 on either side of an extended runway centerline.
1.60

Other Site Dimension and Tolerances

1.61 Azimuth Aiming

Each light unit shall be aimed outward into the approach zone on a line parallel to the helipad centerline
within a tolerance of +/- 1/2 degree.
1.62 Mounting Height Tolerances
The beam centers of all light units shall be within +/- 1 inch of a horizontal plane. This horizontal plane shall
be within +/- 1 foot (0. 3m) of the elevation of the helipad centerline at the intercept point of the visual glide
path with the helipad (except for the condition at 1.67 below).
1.63 Tolerance Along Line Perpendicular to Helipad
The front face of each light unit in a bar should be located on a line perpendicular to the helipad centerline
within +/- 6 inches.

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SECTION TWO

INSTALLATION

2.00
Installation Overview
The ZA737/757 CHAPI system requires several steps to insure proper installation and maximum
performance. Consultation and approval with a civil engineer is highly recommended for proper installation.
These are the basic steps for installing the CHAPI:
* Determination of proper location of the light boxes.
* Installation of the footers and mounting pads.
* Interconnect wiring and home run (star topology) wiring.
* Alignment of the light box assemblies.
* Electrical adjustments.
* Flight check.
Included with your CHAPI is a hardware package, containing the necessary components for the bracket assemblies,
unit mounting screws and studs, which enables the unit to be mounted to the base unit assembly.
2.10

Determination of Proper Light Boxes

To obtain an optimized approach system, several factors must be considered. These are:
* What is the desired threshold crossing height?
* What is the desired glide slope angle?
* Will the selection of the above parameters satisfy the required obstacle clearance angle?

NOTE:
If nearby trees are an obstacle to your approach, allowances should be made in siting your system, because
the trees will continue to grow and could become a serious hazard.
2.11 CHAPI Light Housing Location
Location of CHAPI units shall be in accordance with local licensing authority requirements. See Figure 1 for general
layout dimensions.
2.20 Installation of Footers and Mounting Pads
Once the elevation and exact physical location of the light boxes has been determined, footers should be
prepared as depicted in drawing FLP28407A/B (see section 5). After the footers have been set up, the EMT
(2") legs should be cut. Because of the legs and mounting hardware, 16" is the minimum height that the
center of the light box will be above the mounting surface. To determine the length to cut the EMT legs,
subtract 11.25" from the height of the proposed mounting center of the light box lens, above the mounting
pad. Mount the light boxes and power supply on the pads.
2.21 Align and Secure the Base Unit
* Locate the base unit assembly onto packing blocks, (i.e. wood or metal), placed on the top of the foundation.
* Level the base unit assembly using shims under packing blocks and a standard builders spirit level.
* Align the base unit assembly to the appropriate toe-out angle, in accordance with the layout for a particular
Airport.
* Mix and pour concrete, to retain the base unit in place. The top of the concrete to be level with the marks on each
leg of the base unit assembly, approximately 0.787 inches below the leg securing bolts. DO NOT cover these bolts.
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2.30

Interconnect Wiring
WARNING!
Turning the circuit breaker (CB1) to OFF does NOT remove All voltages.
TB1, SA1/2, and CB1 are still HOT!

2.31 Home Run Wiring Choice

The home run wiring size should be carefully selected to insure optimum performance of the system. Select
the size as indicated by plans and specifications. If the power unit is located within 30' of the light box, #10
wire is adequate for the lamp circuit, and #14 wire is adequate for the tilt switch circuit.
2.32 Above Ground Wiring Protection
To protect the wiring between the light box assembly and the point at which it goes underground, 1"
watertight flex duct is a good selection. It can be terminated in a 1" conduct (pipe) sweep to interface to the
trench.
2.33 Wiring Connections
*Connect 240 VAC to terminals Marked 240V of the power adapter.
*Connect a ground rod ground to the power supply ground lug.
*Connect all light box assembles to the Power Supply. Please refer to the appropriate wiring diagrams
the back of the manual.

at

Install and connect the twist lock photocell in its socket on top of the power supply. Orient the window of the
photocell away from the runway to prevent aircraft landing lights from switching the photocell. Orient the
fixture facing north for best results. Test the PEC by covering the cell. Lights should dim in 40 seconds.
2.40
Adjustment of the Light Housing Assembly (LHA)
The Aiming Device consists of precision machined aluminum blocks corresponding to the particular angles
required by Glide Slope and number of boxes. There are 5 blocks for a four box system and 3 blocks for a
two box system with standard CHAPI Glide Slope Angle of 6 degrees. Non standard Glide Slopes will
require special sets of aiming blocks. The Aiming Blocks are designed to be set on the edge of the light box
with the provided spirit level on the top surface. Refer to Figs. 1 & 2

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Figure 1 - Aiming Device positioning.

2.41 L-881 (Two LHA system)
The Light Housing Assembly nearest the helipad should be adjusted to the Glide Slope Angle + 1/4 degree (
+15 minutes). The light box assembly farthest from the helipad should be adjusted to the Glide Slope Angle
- 1/4 degree (-15 minutes). When the LHAs are in place, make sure both are adjusted with the adjustment
jacks so that the center of the LHA lens are at the same elevation. Remove the cover from the Light Housing
Assembly.
For horizontal alignment place the 6" spirit level across the light box, either on the lens housing or reflector
housing. Adjust the forward nuts on the adjustment jacks to bring the spirit level to center.
For each 1/4 turn executed on the nut on one side, turn the nut on the other side 1/4 turn in the opposite
direction. This will keep the lens center at the same elevation at all times during adjustment. Recheck both
points.
Position the proper aiming block on the edge of the light box for vertical alignment. Place the spirit level on
the aiming block. Adjust the both rear adjustment jacks to bring the spirit level to center. Next, tighten the
bolts holding the pivots. These are accessible underneath the unit at the forward corners.
Recheck the horizontal adjustment at points at each corner and adjust as required. Tighten all nuts securely.
Recheck the vertical adjustment, then tighten all nuts on the new pivot. Last, place the level on top of the tilt
switch. Adjust the tilt switch until the spirit level is centered. Tighten the bolts to hold the tilt switch secure.
Replace the cover on the light box assembly.
2.42 L-880 (four LHA system)
The Light Housing Assembly nearest the helipad should be adjusted to the Glide Slope Angle + 1/2 degree (
+30 minutes). The next adjacent Light Housing Assembly should be adjusted to the Glide Slope Angle + 1/6
degree (+10 minutes). The next adjacent Light Housing Assembly should be adjusted to the Glide Slope
Angle - 1/6 degree (-10 minutes). The next adjacent Light Housing Assembly should be adjusted to the Glide
Slope Angle - 1/2 degree (-30 minutes). When the LHAs are in place, make sure both are adjusted with the
adjustment jacks so that the center of the lens of all boxes are at the same elevation. Remove the cover from
the light box assembly.
For horizontal alignment place the 6" spirit level across the light box, either on the lens housing or reflector
housing. Adjust the forward nuts on the adjustment jacks to bring the spirit level to center.
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For each 1/4 turn executed on the nut on one side, turn the nut on the other side 1/4 turn in the opposite
direction. This will keep the lens center at the same elevation at all times during adjustment. Recheck both
points.
Position the proper aiming block on the edge of the light box for vertical alignment. Place the spirit level on
the aiming block. Adjust the both rear adjustment jacks to bring the spirit level to center.

Figure 2 - Spirit level placed on Aiming Device.

Next, tighten the bolts holding the pivots. These are accessible underneath the unit at the forward corners.
Recheck the horizontal adjustment and adjust as required. Tighten all nuts securely.
Recheck the vertical adjustment, then tighten all nuts on the new pivot. Last, place the level on top of the tilt
switch. Adjust the tilt switch until the spirit level is centered. Tighten the bolts to hold the tilt switch secure.
Replace the cover on the light box assembly.
2.50 Color Filter Installation and Electrical Adjustments
When installing the color filters, as viewed from the rear, select the indicated serial numbered filter set and
install so that TCR is positioned top, center,(toward the center of the light box) and to the rear. This is
marked on each color filter.
After each light box assembly has been properly aligned, and the tilt switches properly set, the system is
ready to be turned on.
Apply power to the system and energize the circuit breaker (CB1) in the Power Supply.
The lamps in all light boxes should now be ON.
CAUTION!
Do not look directly into the front of the light box because the light beam is very intense at that point.
Assuming it is daytime, the power supply should be adjusted to produce approximately 6.6 amps of current as
read on the amp meter in the power adapter. If the amp meter reads less than 6.6 amps, turn the circuit
breaker OFF. Move the input to TB2-5 to the next lower numbered terminal, i.e. change from #5 to #4
would increase the amperage. At night the amperage should be 4.8 amperes.

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Turn the circuit breaker ON. check the amp meter for 6.6 amps. Continue this procedure until the current is
as close to 6.6 amps as possible, but in no case, exceeding 6.6 amp.
Clean out the residue from the power supply and neatly dress the wiring.
Be sure that all light boxes and the power supply are connected to ground rod ground.
Close the door of the power supply and secure its latch.
2.51 Lamp Installation
Install LA-6373 lamps into each light box assemblys lamp holder.
CAUTION!
Do not touch the quartz tube of the LA-4373 lamp as finger oils will
significantly reduce lamp life. If touched, clean with rubbing alcohol.
2.52 Interlock Adjustment, set in over-current mode (optional feature only)
The 77-ECS31BC current monitor is set at the factory to turn on when the current being sensed rises to a
level greater than 6.3 amps after a time delay. This internal delay may require adjustment based upon airfield
operational requirements, but set to minimum unless advised otherwise. Apply power to the runway lights at
the required operational step. Fine-tune the trip point by turning the adjustment and watching the LED. The
LED will light indicating over-current. When a over-current is sensed (LED ON), the output relay is
energized. This is the normal state when the runway lights are energized.
2.60 Flight Check
Before placing in service, the system should be thoroughly flight checked. The flight check should include
flying over any and all obstructions in the approach area to be sure that all light boxes show red whenever
you are close to the obstructions. Several normal approaches should be made to insure good signal at all
points in the approach path.

SECTION THREE

SYSTEM DESCRIPTION AND COMPONENTS

3.00 Principal Components

The model ZAZ737/757 CHAPI A Style system consists of the following main components:
Light Box Assemblies (Qty 4 for L880; 2 for L881)
Power Adapter (qty 1)
Mounting Hardware
Aiming Device with precision 6" Spirit Level
3.10 Light Housing Assembly
The Light Housing Assembly (LHA) is a stable optical platform which supports the lamp, reflector, lenses,
color filter, and tilt switch. Light from the lamp is collected and focused into the plano-convex lens set. This
combination produces the field of illumination into the approach area. Concurrent with the illumination, a red
filter is located at the focal point of the plano-convex lens set as one would view the light box from the
approach area. The transition zone is factory adjusted so it agrees with the calibrated scale on the alignment
arrow assembly. When the Light Housing Assembly is being adjusted, the process elevates the front of the
LHA so the transition zone is set to the desired angle of inclination (alignment angle). It is extremely
important that when the LHA is aligned in the field, all bolts and nuts are tightened properly, then alignment
rechecked to insure accuracy. The Lamp is Flight Light PN: LA-6373, 200W, 6.6A.
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3.20 Power Adapter

The Power Adapter sub-system converts the 240 VAC input voltage to 6.6 amps out to operate the lamps.
This is accomplished by transformers T1 (and T2 in a 4 box system) which provide lower amperage taps so
the lamps can be dimmed for nighttime service. Following is a description of the purpose of the main
components in the power supply:
SA1/2
CB1
T1(or T2)
PEC
RTE-P21
M1
CR1 & CR2
CR3 & CR4
Monitor
K1
PS1

Provides basic lightning surge protection of the 240 VAC input.

Circuit over-current protection and ON/OFF switch.
Power transformer(s): convert the input 240 VAC to standard output current
to control lamp brightness.
Photo Electric Controller (Photocell): detects night or day condition and provides
signal (1=night, 0=day).
Tilt failure detector and delay timer - adjustable - set to 30 seconds in factory.
0 - 10 Meter: provides visual indication of lamp current and assists in prevention
of over-driving the lamps. Its accuracy is 2%.
Lamp intensity step-down relay: Energized during low light levels.
Lamp/tilt circuit control element - normally energized. Tilt failures de-energize
this unit with delay set by RTE-P21. This turns OFF all lamps.
This is an optional unit used to provide interlock to runway lighting circuits.
Control relay for optional interlock control.
Power supply for stable timer and monitor operation.

3.30 Day/Night Control

By utilizing a PEC and a DPST relay, the controller can automatically switch between two different
brightness levels depending on ambient light levels. This in essence provides day/night brightness levels.
During daylight the PECs output will be de-energized. Relays CR1 and CR2 will be de-energized. During
night operation, the PECs output is energized which in turn energizes the relays CR1 and CR2. Minimum
rated current is supplied to the lamps from T1/T2.
This reduced lamp current (4.8A) intensity insures pilot safety and convenience. By design in the event of
component failure, the system will default to the night brightness level for insured aircraft safety or shut
down completely with tilt failures.
3.40 Power Protection Circuit
The power regulation circuit consists of a 15 amp circuit breaker, and multi-tap transformers (T1 and T2). In
operation CB1 acts as the ON/OFF switch while providing circuit over-current protection. SA1 and SA2
provide basic lightning surge protection to the entire unit. The multi-tap power transformer(s) allows
adjustment of both the day and night brightness levels via the taps on the secondary side.
3.50 Tilt Detection Circuit
To insure aircraft safety by preventing out-of-alignment systems from operating, a tilt detection circuit has
been incorporated into the controller. This circuit utilizes a time delay feature to screen out false signals due
to vibrations. In normal operation with a closed tilt loop switch-loop,
NOTE: BOTH RTE & P21 LEDS WILL BE ON.
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Should the tilt circuit fail, the Mode LED (top) will extinguish after the delay period which was factory
adjusted to 30 seconds. At no time should this or any other safety feature be bypassed or modified. To do so
will risk aircraft safety.
3.60 Lens Heater Circuit, Class II only
In severe winter climates, the lens must be heated to insure dependable operation in all weather conditions.
This is accomplished by a power resistor in series with each lamp filament. It dissipates approximately 20
watts into its heater mount; this insures complete lens heat absorption and dependable signal presentation to
pilots.
3.70 Alignment & Aiming Device Calibration
This component has two parts. The structural component shown in Figure 2 has no calibration. It has been
factory checked for accuracy and cannot be altered without damage to the frame. The adjustable precision
spirit level is shown in Figure 3. The level was factory aligned and should not require adjustment, but if this
were ever necessary, the check and alignment is quite simple:
A. Use any flat level surface - the more level and stable the better. Insure the surface is clean, and that
the bottom of the level is also clean.
B. Place the level on the inspected area, marking its location. Now, reverse the level (turn it 180
degrees). The bubble MUST be in the same relative position on the scale.
C. With each movement of the level, give the bubble time to become stable.
D. Should the bubble NOT be in the same relative position, loosen the adjustment nuts and correct for
one-half of the difference in the readings. Re-tighten the nuts. Repeat steps B, C, and D until there is no
difference. This completes the Alignment and Aiming Devices calibration. It should be accomplished
before each use, or at least semi-annually.
SECTION FOUR TROUBLESHOOTING
4.00 Troubleshooting
Your system has been designed to provide years of trouble-free operation. The following pointers will help
you locate and correct common problems. It is assumed that all interconnect wiring is good and that tilt
switches are aligned and have continuity.
Symptom

Likely Problem

CLASS I or CLASS II
Lamp OUT

Check lamp (if either lamp burns out, it would

not shut off the other lamp).

Photocell operation
reversed (dim in daylight)

Check wiring of PEC toTB3 (color coded

red/blk/wht).

CLASS II ONLY
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Lamp not ON

Temporarily short TB1B, R1-1

and R1-2, then R2-1 and R2-2.
As each is tested, if the failed
lamp turns ON, the heater resistor
may have failed. Check for .5 ohm
resistance - replace if required.

CLASS I or CLASS II
Lamps do not light
(RTE-P21 mode light out)

Temporarily short Power Supply

TB1 T-1 and TB1 T-2 and engage
CB1. If system now functions,
problem is either switches or tilt
switch wiring.
If problem is determined to be a
particular tilt switch, readjust tilt switch
by going through zero and then back.
DO NOT LEAVE JUMPER IN PLACE!

Light Housing Alignment

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Footers not stable.

Mounting hardware is not tight.
Check floor flanges, nuts
on frangible couplings, bolts & nuts
on light box.

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ZA737/757 CHAPI Parts List (Style A and B)

Flight Light Part Number

Description

15-201TSA

PAPI Tilt Switch Assy. A

Components:
15-FFF2X425
LA-6373
77-203
77-204
77-206
77-207
77-249-117
77-282-402
77-282-601
77-HC83314SS
77-HS83314
77-REG5803-S
77-REG616
77-REG8413
80-015053
80-016045
80-019035
80-032081
80-021077
80-021253
80-021254
Lens heater Class II

FAA Frangible Floor Flange

200W 6.6A Quartz G6.35
Tilt switch mounting plate
Adapter, all-thread
Pivot, LHA
Filter holder
End Stop
Jumper, adjacent
Terminal block, gray, 315
Catch, stainless steel
Strike, stainless steel
Connector, 1 LT metallic, ins.
EMT coupling, 2
Reducer, 2 to 1
ZA757/4 Lamp Holder assembly
ZA757/4 lens assembly
ZA757/4 filter glass, red
CHAPI filter frame assembly red/white/green
Hatch cover
ZA757/4 filter spring
ZA757/4 reflector assembly

77-215
77-281-604
77-821-604
77-880-0604
15-7x7LHA-X

Lens heater mount

Terminal block, blue, .236
Jumper
Resistor, 25W, .47 ohm
PAPI Light Housing Assy, B, I/II, Tilt Switch

Components:
15-FFF2X425
77-FA9812103
77-FA9812104
77-FA9812101
77-FA9812102
77-LA-6
77-937-106
77-937-100
77-937-105
77-937-107
77-021042
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FAA Frangible Floor Flange

Printed circuit assembly, master (2lamp)
Printed circuit assembly, slave (2lamp)
Printed circuit assembly, master (3lamp)
Printed circuit assembly, slave (3 lamp)
Ground Lug
Transformer, 240/34 VAC, 60 Hz (ZA737) Class I
Transformer, 240/34 VAC, 60 Hz (ZA757) Class I
Transformer, 240/34 VAC, 60 Hz (ZA757) Class II
Transformer, 240/34 VAC, 60 Hz (ZA737) Class II
Aiming Device ( Block)
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77-#98-6
15-737AD
77-ECS31BC
77-RM2S-UL

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Level, spirit, precision, 6

ZA737 Aiming and Alignment Device
Current Sensor
Relay, 240 VAC

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